GIFT  OF 


ENGINEERING    LIBRARY 
OF 

WILLIAM   B.  STOREY 

A  GRADUATE  OF 

THE   COLLEGE   OF   MECHANICS 
CLASS   OF  1881 

PRESENTED  TO  THE  UNIVERSITY 
1922 


VANADIUM  RAILS 


A  REPORT  OF  TESTS  OF 
VANADIUM  STEEL  RAILS 
WITH  COMPARATIVE 
TESTS  WITH  SIMPLE 
CARBON  STEEL  RAILS 
OF  THE  SAME  SECTION 
AND  MANUFACTURE 

1914 


AMERICAN  VANADIUM 
COMPANY 

VANADIUM  BUILDING,  PITTSBURGH,  PA. 


VANADIUM  RAILS 

Convinced  from  results  along  other  lines  that  the 
use  of  vanadium  in  rail  steel  will  greatly  reduce  rail  failures 
and  at  the  same  time  greatly  increase  the  wearing  quality 
of  the  rails,  the  American  Vanadium  Company  has 
had  several  heats  of  basic  open  hearth  vanadium  steel 
rolled  into  rails  for  test  purposes. 

While  no  question  exists  as  to  the  beneficial  effects 
of  vanadium  in  steel,  the  price  until  the  past  year  has 
been  too  high  to  make  it  commercially  practicable  to  use 
it  in  RAILS. 

It  is  universally  recognized  that  the  rail  situation  is 
one  of  the  most  serious  confronting  the  railroad  officials 
today. 

Considerations,  primarily  of  safety,  and  also  of 
economy,  urgently  demand  a  decided  improvement  in 
the  quality  of  rail  steel. 

The  tonnage  of  rails  for  replacement  purposes  has 
greatly  increased.  Published  estimates  from  the  statistics 
available  place  this  increase  at  50  per  cent,  over  that  of  a 
few  years  ago,  or  an  increase  from  1,000,000  tons  annually 
to  fully  1,500,000  tons. 

The  railroads  and  rail  makers  have  tried  to  meet  the 
situation  by  increasing  the  weight  of  the  rail  section.  At 
the  same  time  harder,  higher  carbon  steels  have  been 
used  in  the  effort  to  obtain  increased  strength  and  wear- 
ing qualities;  until  now  rails  are  rolled  from  practically 
spring  steel,  or  low  grade  tool  steel. 

The  result,  although  attended  with  some  degree  of 
success,  has  failed  to  lessen  rail  breakage.  On  the  con- 
trary, the  use  of  high  carbon  steel  has  introduced  new 
causes  of  failure;  namely,  internal  fissures,  commonly 
known  as  "silvery  oval  spots". 

It  is  evident  that  a  steel  of  greater  strength,  tough- 
ness and  better  wearing  qualities,  together  with  greater 


501801 


VANADIUM      RAILS 

homogeneity  and  freedom  from  segregation,  than  simple 
carbon  steel,  is  required  to  meet  the  situation. 

Through  the  addition  of  a  small  percentage  of 
vanadium  to  simple  carbon  standard  rail  steel,  rails  of 
exceptionally  great  strength,  toughness  and  wearing 
qualites  are  obtained.  This  is  shown  by  the  tests  given  in 
the  following  pages  in  which  comparison  is  also  made  with 
corresponding  tests  from  simple  carbon  steel  rails  of  the 
same  section  rolled  at  the  same  time  by  the  same  mill. 

Briefly  summarized,  the  salient  facts  as  shown  by 
analysis  of  the  results  of  the  tests  are  as  follows: 

SUMMARY 

MANUFACTURE:  The  manufacture  of  rails  from 
vanadium  steel  does  not  require  any  change  in  the  usual 
rail  mill  practice.  The  steel  rolls  clean  and  shows  no 
tendency  to  crack  or  tear.  No  change  is  necessary  in  the 
gauges ;  as  vanadium  steel  takes  the  same  standard  gauge 
as  simple  carbon  steel.  Nothing  developed  in  the  melt- 
ing, casting,  heating  or  rolling  of  these  heats  of  vanadium 
steel  to  indicate  that  the  mill  output  will  in  any  way 
be  reduced.  The  percentage  of  yield  of  rails  from  the 
ingots  is  equal  to  or  even  greater  than  for  simple  carbon 
steel  rails;  and  the  evidence  is  that  there  will  be  less 
scrap  from  cracking  or  tearing  in  the  rolls,  and  also  that 
the  percentage  of  second  quality  rails  will  be  less. 

DROP  TESTS:  The  vanadium  steel  rails  met  all 
the  requirements  specified  for  ductility  and  deflection  and 
are  stiff er  or  more  resilient  than  the  100-lb.  carbon 
steel  rails  of  the  same  section,  with  which  they  were 
compared.  The  vanadium  steel  rails  deflected  about 
the  same  amount  from  an  18-ft.  blow  as  the  carbon  steel 
rails  did  from  a  15-ft.  blow. 

TENSILE  TESTS:  The  vanadium  steel  rails  show  an 
elastic  limit,  or  useful  strength  averaging,  over  40% 
higher  than  for  the  simple  carbon  steel  rails;  though  the 
latter  had  50%  higher  carbon  content.  The  ratio  of 
elastic  limit  to  tensile  or  breaking  strength  is  70%  or 
more  for  the  vanadium  steel  rails  as  compared  with  about 


VANADIUM      RAILS 

57%  for  the  carbon  steel  rails.  The  ductility  or  tough- 
ness of  the  vanadium  steel  rails  also  shows  higher  than 
for  the  carbon  steel  rails.  These  tests  are  a  direct 
measurement  of  the  superiority  of  the  vanadium  over 
the  carbon  steel  rails. 

ALTERNATING  IMPACT  TESTS:  These  tests  prove 
that  vanadium  steel  of  the  high  elastic  limit  shown  by 
these  rails  has  great  endurance  under  repeated  stresses 
and  is  free  from  brittleness. 

BEND  TESTS:  Although  the  vanadium  steel  rails 
are  very  much  harder  than  the  simple  carbon  steel  rails 
with  which  they  are  compared,  the  bend  tests  are  equally 
as  good. 

HARDNESS  TESTS:  The  vanadium  steel  rails  show 
great  uniformity  of  hardness  throughout  the  entire 
section;  and  are  from  10%  to  35%  harder  than  the  carbon 
steel  rails  of  50%  higher  percentage  of  carbon.  This 
superior  hardness,  combined  with  the  high  elastic  limit 
and  the  great  toughness  of  the  vanadium  steel  rails 
indicate  a  great  increase  in  wear  resisting  qualities. 

WEAR  TESTS:  Comparative  tests  to  determine 
resistance  to  wear  show  a  very  great  increase  in  wear 
resisting  qualities  for  the  vanadium  over  the  simple  carbon 
steel  rails. 

CHEMICAL  UNIFORMITY  (SEGREGATION)  :  The  vana- 
dium steel  rails  show  no  segregation,  the  variations  in 
analysis  noted  being  within  the  allowable  limits  of 
analytical  error.  The  standard  high  carbon  steel  rails 
usually  show  segregation  and  in  the  case  of  the  "A"  rails 
the  segregation  is  frequently  very  marked. 

HOMOGENEITY  AND  DENSITY:  Sections  from  the 
vanadium  steel  rails  etched  with  boiling  dilute  sulphuric 
acid  show  a  remarkably  dense,  uniform  structure,  free 
from  piping,  slag  and  other  defects.  The  contrast  in 
this  respect  with  the  etched  sections  of  the  carbon  steel 
rails,  as  shown  in  the  accompanying  reproductions  of 
photographs,  is  very  striking.  The  carbon  rails  were 
selected  at  random  by  the  makers. 


VANADIUM      RAILS 


i 


VANADIUM  STEEL  HEAT  26813,  RAIL  "A" 

Shows  only  a  slight  amount  of  piping  at  the  top  of  the  web  and  in  the  web.  The 
appearance  of  the  center  of  the  head  of  this  etched  section  would  indicate  that  the 
center  of  the  top  of  the  ingot  was  a  little  soft  or  green  when  bloomed.  A  few  of  the 
ingots  from  this  heat  were  heavily  cropped  at  the  bloom  shears  on  this  account. 


VANADIUM     RAILS 


VANADIUM  STEEL  HEAT  26813,  RAIL  "B" 
Shows  a  very  solid,  uniform,  dense  structure. 


VANADIUM      RAILS 


VANADIUM  STEEL  HEAT  27989,  RAIL  "A" 
Shows  a  perfectly  uniform,  dense  structure  with  no  evidence  of  residual  piping. 


VANADIUM      RAILS 


. 


VANADIUM  STEEL  HEAT  27993,  RAIL  "A" 

Shows  a  uniform,  dense  structure,  with  only  the  very  slightest  indication  of 
residual  piping 


9 


VANADIUM      RAILS 


CARBON  STEEL,  RAIL  "A" 

Is  typical  of  most  "A"  rail  structures  and  is  really  better  than  many;  because  more 

than  the  usual  discard  was  made  from  the  top  of  the  ingots  in  rolling 

this  lot  of  rails 


10 


VANADIUM      RAILS 


CARBON  STEEL,  RAIL  "B" 
Shows  residual  piping,  quite  marked  on  the  left  side  of  the  etching 


11 


VANADIUM      RAILS 


Three   heats   of   vanadium   steel   were   made  to  the  following 
chemical  specifications : 


Heat 
26813 

Heat 

27989 

Heat 
27993 

Carbon  
Manganese  
Silicon  
Phosphorus  
Sulphur  
Vanadium  

.  45  to     .  65% 
1.10  to  1.40% 
under  .  20% 
under  .05% 
under  .05% 
4  Ibs.  to  ton 

.40  to     .52% 
1.00  to  1.30% 
under  .20% 
under  .05% 
under  .05% 
4  Ibs.  to  ton 

.60  to     .75% 
.75  to  1.00% 
under  .20% 
under  .05% 
under  .05% 
4  Ibs.  to  ton 

In  the  first  two  heats,  the  manganese  specified  is  higher  than 
usual;  as  previous  investigations  have  shown  that  with  manganese 
somewhat  higher  than  usual  the  effect  of  the  vanadium  on  the 
physical  properties  of  the  steel  is  still  further  increased.  The  third 
heat,  however,  conforms  to  the  usual  specification  for  rail  steel. 

The  actual  chemical  compositions  of  these  three  heats  are: 


Heat 

26813 

Heat 

27989 

Heat 
27993 

Carbon        .... 

.550% 

.510% 

.558% 

Manganese  
Silicon    ...      .          .        

1.510% 

.170% 

1.110% 

.120% 

.780% 
.158% 

Phosphorus  
.    Sulphur  
Vanadium  
Actual  per  cent.  Vanadium  added 

.015% 
.019% 

-148% 
168% 

.010% 
.029% 
.  146% 

160% 

.017% 
.025% 
.156% 

.177% 

Heat  26813 — The  manganese  is  higher  than  called  for,  due  to 
the  percentage  of  loss  in  manganese  addition  not  being  nearly  as 
great  as  allowed  for  in  usual  practice. 

Heat  27993 — The  percentage  of  carbon  is  about  5  points  below 
the  limit  called  for,  due  to  various  mill  delays. 

PRODUCTION 

The  production  percentage,  or  yield  of  rails  per  ton  of  ingots,  is 
higher  than  usual;  although  from  the  evidence  of  the  tests  which  follow 
it  seems  as  though  it  might  be  possible  to  obtain  even  higher  yields. 


Date  

4-22-14 

7-27-14 

7-27-14 

Heat.....  
Ingots,  weight  

26813 
121,000  Ibs. 

27989 
104,400  Ibs. 

27993 
108,000  Ibs. 

Rails,  weight 

89,500  Ibs. 

80,200  Ibs. 

82,  000  Ibs. 

Rails,  number  
Rails,  scrap  
Per  cent,  yield  

77-lst,  5-2nd 
none 
74.0 

73-lst,  l-2nd 
none 
76.9 

73-lst,  2-2nd 
none 
75.9 

12 


VANADIUM      RAILS 

All  three  vanadium  steel  heats  rolled  perfectly.  The  blooms 
were  clean  and  free  from  seams  and  cracks,  and  no  scrap  rails  were 
produced.  The  standard  gauges  were  used;  showing  that  the  shrink- 
age of  the  steel  is  the  same  as  for  standard  carbon  steel,  and  that  no 
change  in  this  respect  is  necessary.  Nothing  developed  in  the 
heating  and  rolling  to  indicate  that  the  mill  output  would  be  in  any 
way  reduced  by  the  use  of  vanadium  steel.  The  top  portion  of 
some  of  the  ingots  from  the  first  heat,  26813,  were  a  little  soft  or 
green  when  bloomed,  and  were  cropped  heavily  on  this  account. 

DROP  TESTS 

When  the  first  heat,  26813,  was  made,  it  was  arranged  to  make 
drop  tests  on  crop  ends  from  both  the  "A"  and  "B"  rail  of  three 
ingots,  representing  the  beginning,  middle  and  end  of  the  pouring. 
Through  misunderstanding,  this  was  not  carried  out  on  the  second 
heat,  27989;  and  only  three  drop  tests  were  made  from  this  heat, 
one  being  from  a  "C"  rail  crop;  as  the  top  blooms  from  the  ingots 
were  rolled  into  3-rail  lengths.  The  arrangement  for  two  drop  tests 
from  the  beginning,  middle  and  end  of  the  third  heat,  27993,  was 
carried  out,  excepting  that  the  tests  were  made  on  "C"  rail  crops 
instead  of  "B"  rail;  on  account  of  the  top  blooms  all  having  been 
rolled  into  3-rail  lengths. 

The  usual  requirements  for  drop  test  were  followed,  excepting 
that  the  height  of  the  drop  was  increased  from  15  ft.  to  18  ft.  for 
the  vanadium  rails.  Two  vanadium  rails  from  the  first  heat,  however, 
were  tested  with  the  height  of  the  drop  at  15  ft.;  in  order  to  get  a 
direct  comparison  with  the  carbon  steel  rails.  One  vanadium  rail 
was  tested  with  the  flange  up.  All  the  others  were  tested  in  the 
usual  manner  with  the  head  up. 

Six  one-inch  spaces  were  laid  off  on  the  bottom  of  the  flange;  in 
order  to  determine  the  ductility  or  stretch  after  each  blow  of  the 
drop,  the  requirements  being  5%  or  5-100-inch  stretch  in  two  adjacent 
inch  spaces. 

As  will  be  seen,  the  vanadium  steel  rails  met  all  the  require- 
ments specified  for  ductility  and  deflection.  At  the  same  time,  they 
show  up  stiff er  under  the  drop  test  than  the  carbon  steel  rails. 

The  chemical  specifications  to  which  the  carbon  steel  rails  were 
made  are: 


Carbon 62  to  .  75% 

Manganese 60  to  .  90% 

Silicon Under  .  20% 

Phosphorus Under  .  04% 

13 


VANADIUM      RAILS 


DROP    TESTS 
VANADIUM  RAILS 


Heat  No. 

0 

£ 

1 

1 

:! 
l| 

fflQ 

P 

J3 

5 

"o 

i 

Deflection 
in  Inches 

Elongation  in  Hundredths  of  an  Inch 

Fracture 

Per  Inch 

Total 

lin. 

2  in. 

3  in. 

4  in. 

5  in. 

6  in. 

26813 

16 

A 

15 

i 

2 

0.7 
1.4 

4 
5 

3 
6 

5 

8 

4 

7 

4 

7 

2 
5 

22 
38 

Clear 

3 

3.2 

16 

19 

17 

17 

14 

1 

0.9 

3 

5 

4 

4 

3 

3 

22 

2 

1.6 

6 

9 

8 

7 

4 

4 

38 

26813 

16 

B 

15 

3 

2.3 

8 

12 

12 

10 

6 

5 

53 

Clear 

4 

2.9 

13 

16 

14 

10 

6 

5 

64 

5 

3.7 

17 

23 

20 

14 

8 

6 

88 

6 

4.6 

18 

19 

13 

8 

6 

26813 

1 

A 

18 
Flange 
Up 

1 

2 

1.0 
1.7 

5 
6 

6 

7 

7 
9 

6 
8 

5 

GO  GO 

32 

Clear 

1 

1.1 

4 

6 

6 

4 

3 

3 

26 

2 

1.8 

8 

9 

9 

6 

4 

4 

40 

26813 

1 

B 

18 

3 

2.7 

12 

14 

11 

8 

4 

4 

53 

Clear 

4 

3.6 

15 

16 

14 

10 

7 

5 

67 

5 

3.7 

16 

14 

10 

6 

4 

26813 

9 

A 

18 

1 

1.0 

4 

4 

5 

5 

4 

2 

24 

2 

1.8 

4 

4 

5 

5 

3 

*Web  Piped 

1 

1.0 

3 

4 

5 

5 

5 

4 

26 

26813 

9 

B 

18 

2 

1.8 

5 

6 

8 

8 

8 

5 

40 

Clear 

3 

2.6 

6 

8 

10 

7 

1 

1.0 

3 

4 

5 

5 

4 

2 

23 

27989 

1 

A 

18 

2 

1.9 

4 

5 

7 

10 

10 

9 

45 

Clear 

3 

5 

8 

11 

11 

11 

9 

55 

1 

1.1 

3 

4 

5 

5 

5 

5 

27 

27989 

6 

C 

18 

2 

2.1 

5 

5 

7 

10 

10 

9 

46 

Clear 

3 

7 

8 

12 

13 

12 

10 

62 

1 

1.1 

2 

3 

5 

5 

5 

5 

25 

27989 

14 

A 

18 

2 

2.0 

5 

7 

10 

10 

8 

6 

46 

Clear 

3 

7 

11 

16 

15 

13 

10 

72 

1 

1.0 

3 

3 

4 

4 

4 

4 

22 

27993 

1 

A 

18 

2 

1.9 

4 

6 

7 

8 

8 

7 

40 

Clear 

3 

7 

7 

9 

9 

10 

8 

50 

27993 

1 

C 

18 

1 
2 

1.1 

3 
4 

4 
5 

5 

7 

5 
9 

5 

8 

4 

8 

26 
41 

Clear 

27993 

6 

A 

18 

1 
2 

1.1 

2 
3 

3 
4 

4 
5 

5 

7 

5 

7 

5 

7 

24 
33 

Clear 

14 


VANADIUM      RAILS 


DROP  TESTS— Continued 

VANADIUM  RAILS 


6 

"o? 

I 

C* 

Elongation  in  Hundredths  of  an  Inch 

1 

- 

J3     . 

S 

ti-5 

Per  Inch 

$ 

1 

" 

P 

o 
6 

nS 

lin. 

2  in. 

3  in. 

4  in. 

Sin. 

6  in. 

Total 

Fracture 

Z 

1 

1.1 

3 

4 

5 

5 

4 

3 

24 

27993 

6 

C 

18 

2 

2.0 

6 

8 

9 

9 

8 

6 

46 

Clear 

3 

7 

8 

11 

10 

10 

8 

54 

1 

1.2 

4 

5 

5 

5 

5 

4 

28 

27993 

14 

A 

18 

2 
3 

2.2 
3.2 

6 

8 

7 
9 

9 
11 

8 
10 

8 
10 

8 
12 

46 
60 

Clear 

4 

8 

9 

11 

12 

13 

14 

67 

1 

1.1 

3 

4 

4 

5 

5 

4 

25 

27993 

14 

C 

18 

2 

2.1 

6 

8 

10 

10 

8 

6 

48 

Clear 

3 

8 

11 

15 

15 

11 

8 

68 

CARBON  RAILS 


a 

^ 

§S 

Elongation  in  Hundredths  of  an  inch 

fa 

0  | 

6-2 

1| 

Per  Inch 

Fracture 

I 

KQ 

|3 

Is 

lin. 

2  in. 

3  in. 

4  in. 

Sin. 

6  in. 

Total 

1 

1.0 

3 

4 

4 

3 

3 

3 

20 

i 

15 

2 

1.9 

5 

6 

7 

7 

7 

5 

37 

Clear 

3 

Nicked 

1 

1.0 

4 

4 

4 

3 

3 

2 

20 

2 

15 

2 

1.8 

5 

6 

7 

7 

6 

5 

36 

Clear 

3 

Nicked 

3 

15 

1 

1.1 

4 

4 

5 

5 

4 

3 

25 

Clear 

2 

Nicked 

*A  very  small  indication  of  piping  which  showed  on  one  side  only  of  the  wedge- 
shaped  piece  broken  out  when  the  rail  broke  under  the  drop. 

In  addition  to  drop  tests,  one  full  length  "A"  rail  from  each  of 
the  three  vanadium  heats  was  broken  into  ten  pieces  and  the  fractures 
carefully  examined  for  evidence  of  piping.  Every  fracture  was  found 
to  be  free  from  any  evidence  of  piping. 

PHYSICAL  TESTS 

Tensile  tests,  alternating  impact,  and  bend  tests  were  made  from 
rail  crops  from  each  heat,  and  also  wear  and  hardness  tests.  The 
crops  from  the  "A"  rails  were  taken  from  the  top  end  of  the  rail. 

15 


VANADIUM      RAILS 


Tensile  tests  were  also  made  from  the  middle  section  of  each  of  the 
vanadium  steel  rails  which  were  broken  under  the  gag  press.  Corre- 
sponding tests  for  comparison  were  made  from  an  "A"  and  "B" 
100-lb.  section  carbon  steel  rail.  These  tests  are  shown  in  the  fol- 
lowing table;  and  the  locations  of  the  tests  are  indicated  on  the 
accompanying  illustrations. 

Due  to  the  more  rapid  cooling  of  the  rail  crops,  the  tests  from 
these  show  a  little  higher  in  elastic  limit  than  the  tests  from  the  mid- 
section  of  the  three  rails  broken  in  the  gag  press ;  as  these  rails  cooled 
much  more  slowly  on  the  hot  bed. 

TENSILE  TESTS 


FIG.  1 :     Location  of  Tensile 

Tests  Where  5  Tests 

Were  Made. 

FIG.  2 :     Location  of  Tensile 

Tests  Where  8  Tests 

Were  Made. 


Fig.  1 


Fig.  2 


VANADIUM  RAILS 


Heat 
No. 

Rail 

Test 
No. 

Elastic  Limit 
lbs.persq.in. 

Tensile  Strength 
Ibs.  per  sq.  in. 

Elongation  in 
2  in.  per  cent. 

Reduction  of 
Area  per  cent. 

1 

130000 

140000 

12.0 

22.0 

A 

2 

102500 

132500 

5.0 

5.5 

26813 

Crop 

3 

100000 

121000 

Broke  in  Fillet 

4 

107500 

130000 

Broke  in  Fillet 

5 

105000 

123000 

Broke  in  Fillet 

1 

92600 

130000 

12.5 

21.5 

A 

2 

112000 

135000 

13.0 

24.0 

Rail 

3 

90000 

125000 

14.0 

24.5 

(Mid 

4 

98000 

130000 

14.5 

25.5 

26813 

Section) 

5 

95000 

129000 

15.0 

30.0 

6 

105000 

137000 

13.0 

26.5 

7 

92000 

128000 

13.0 

20.5 

8 

99000 

134000 

15.0 

28.0 

1 

92000 

134000 

12.0 

24.0 

2 

95000 

133000 

12.0 

24.0 

B 

3 

97500 

125500 

6.0 

10.0 

26813 

Crop 

4 

100000 

126500 

Broke  in  Fillet 

5 

102500 

140000 

11.0 

20.5 

16 


VANADIUM      RAILS 


TENSILE  TESTS— Continued. 


Heat 
No. 

Rail 

Test 

No. 

ElasticLimit 
Ibs.persq.in. 

Tensile  Strength 
Ibs.  per  sq.  in. 

Elongation  in 
2  in.  per  cent. 

Reduction  of 
Area  per  cent. 

B 

6 

105000 

145000 

10.5 

25.5 

26813 

Crop 

7 

110000 

147500 

9.0 

18.5 

8 

110000 

147500 

10.5 

20.5 

1 

100000 

130500 

13.0 

27.5 

2 

100000 

133000 

12.0 

25.5 

E 

3 

102500 

135000 

11.0 

20.5 

26813 

Crop 

4 

105500 

142000 

11.5 

22.0 

5 

105000 

140000 

12.0 

25.0 

6 

110000 

140000 

12.0 

25.0 

7 

102500 

135000 

12.0 

23.5 

8 

107000 

140000 

12.0 

25.5 

1 

92000 

127000 

13.0 

24.5 

2 

90000 

127000 

12.0 

26.5 

A 

3 

98000 

130500 

12.0 

21.5 

27989 

Crop 

4 

97500 

129500 

13.0 

27.5 

5 

95000 

126000 

14.0 

28.0 

6 

102000 

132500 

13.0 

20.5 

7 

88000 

122000 

12.0 

23.5 

8 

92500 

125000 

13.0 

20.5 

1 

92000 

130000 

14.5 

26.5 

A 

2 

90000 

125000 

15.5 

30.0 

Rail 

3 

97250 

127000 

5.0 

8.0 

JMid 

4 

90000 

138000 

9.0 

10.0 

27989 

Section) 

5 

92500 

130000 

14.5 

25.0 

6 

90000 

126000 

15.0 

30.5 

7 

85000 

124800 

14.0 

26.5 

8 

95000 

127500 

14.5 

29.0 

1 

90500 

123000 

11.5 

16.0 

2 

85000 

120000 

11.5 

18.0 

3 

90500 

117000 

11.0 

16.0 

27993 

A 

4 

96000 

121000 

13.0 

20.5 

Crop 

5 

82500 

118000 

13.0 

26.5 

6 

90000 

125000 

11.0 

17.0 

7 

85000 

122000 

10.0 

15.5 

8 

85000 

125000 

10.0 

17.0 

1 

80000 

118000 

13.0 

22.0 

2 

90000 

126000 

12.5 

24.5 

A 

3 

87500 

125000 

11.5 

17.0 

-  Rail 

4 

80000 

123000 

14.0 

23.0 

27993 

(Mid 

5 

85000 

125500 

12.0 

17.5 

Section) 

6 

85000 

125000 

13.5 

24.5 

7 

80500 

122500 

13.5 

20.5 

8 

80000 

123000 

14.0 

27.0 

17 


VANADIUM      RAILS 


TENSILE  TESTS— Continued. 


CARBON  RAILS 


Heat 
No. 

Rail 

Test 
No. 

ElasticLimit 
lbs.persq.in. 

Tensile  Strength 
Ibs.  per  sq.  in. 

Elongation  in 
2  in.  per  cent. 

Reduction  of 
Area  per  cent. 

1 

63000 

112500 

13.5 

20.5 

2 

66000 

114000 

13.0 

18.5 

3 

65000 

114000 

9.0 

11.0 

4 

66000 

114500 

12.5 

20.0 

A 

5 

65000 

115000 

12.5 

17.0 

6 

65500 

117000 

11.5 

17.0 

7 

65000 

115000 

12.5 

16.0 

8 

70000 

120000 

12.5 

18.5 

1 

60000 

123000 

10.5 

14.5 

2 

46000 

119000 

10.0 

17.0 

3 

65000 

126000 

9.0 

11.5 

4 

72250 

125000 

9.0 

13.5 

B 

5 

75000 

125500 

10.0 

16.0 

6 

70000 

121000 

10.5 

15.0 

7 

57000 

121000 

8.5 

13.5 

8 

80000 

124500 

10.5 

16.0 

These  tests  show  a  decided  increase  in  elastic  limit,  or  useful 
strength,  in  favor  of  the  lower  carbon  vanadium  steel,  without 
sacrifice  of  ductility. 

BEND  AND  ALTERNATING  IMPACT  TESTS 

The  bend  tests  were  made  on  rectangular  pieces  about  8  inches 
long.  The  load  was  applied  6  inches  from  the  fixed  end  of  the  test 
piece.  The  radius  of  the  jaws  holding  the  bend  specimen  was  not 
over  y%  inch,  and  the  edges  of  the  specimens  were  not  rounded. 


FIG.  3:     Location  of 
Bend  Tests. 


FIG.  4:     Location  of  Alter- 
nating Impact  Tests. 


Fig.  3 


Fig.  4 


18 


VANADIUM      RAILS 


The  alternating  impact  tests  are  made  on  bars  turned  to  %  inch 
diameter.  The  bar  is  held  firmly  in  a  vise,  and  the  upper  end  moved 
backwards  and  forwards  by  means  of  a  slotted  arm,  through  a  total 
distance  of  %  inch  at  the  rate  of  600  movements  per  minute.  The 
distance  from  the  vise  to  the  slotted  arm  is  4  inches.  Each  move- 
ment is  accompanied  by  a  blow  on  the  bar  by  the  slotted  arm. 


BEND  TESTS 


Heat 
No. 

Rail 

Test 
No. 

Size 

Degrees 

Test 
No. 

Alt. 
Impacts 

1 

2.125  x  .375 

50 

1 

1464 

26813 

A 

3 

2.0   x  .496 

31 

2 

520 

Vanadium 

Crop 

4 

2.4   x  .455 

42 

3 

1304 

5 

2.4   x  .455 

49 

5 

670 

6 

1600 

1 

2.0   x  .300 

62 

1 

1444 

2 

2.4   x  .287 

21 

2 

1110 

26813 

B 

3 

2.1   x  .533 

29 

3 

1136 

Vanadium 

Crop 

4 

2.3   x  .503 

35 

4 

1268 

5 

2.3   x  .503 

40 

5 

1454 

6 

1540 

7 

1326 

8 

1580 

1 

2.05  x  .30 

62 

1 

960 

2 

2.5   x  .35 

26 

2 

790 

27989 

A 

3 

2.05  x  .55 

55 

3 

964 

Vanadium 

Crop 

4 

2.2   x  .50 

51 

4 

880 

5 

2.45  x  .50 

39 

5 

1210 

1 

1.8   x  .20 

61 

1 

910 

2 

2.5   x  .36 

55 

2 

530 

27993 

A 

3 

2.0   x  .55 

61 

3 

800 

Vanadium 

Crop 

4 

2.5   x  .50 

48 

4 

784 

5 

2.2   x  .50 

52 

5 

1110 

1 

1.9   x  .30 

82 

1 

1441 

2 

2.5   x  .32 

39 

2 

1250 

Carbon 

A 

3 

2.05  x  .50 

57 

3 

1716 

4 

2.3   x  .50 

44 

4 

1820 

5 

2.45  x  .50 

58 

5 

1300 

1 

2.0   x  .365 

47 

1 

1208 

2 

2.0   x  .275 

58 

2 

980 

Carbon 

B 

3 

2.1   x  .506 

47 

3 

1670 

4 

2.3   x  .502 

41 

4 

1476 

5 

2.3   x  .502 

40 

4 

1230 

5 

1604 

6 

1420 

8 

1440 

ALTERNATING 
IMPACT  TESTS 


19 


VANADIUM      RAILS 


HARDNESS  TESTS 

Hardness  tests  were  made  by  the  Brinell  method.  This  method 
of  determining  hardness  consists  of  measuring  the  impression  made 
by  a  standard  steel  ball  under  a  standard  load.  The  tests  were 
made  on  sections  from  the  same  rail  crops  from  which  the  other  tests 
were  made.  The  locations  of  the  tests  are  shown  in  the  accompany- 
ing illustration;  and  the  results  are  given  in  the  following  table. 


LOCATION  OF  HARDNESS  TESTS 

20 


VANADIUM      RAILS 


The  sections  from  heat  26813  showed  an  average  hardness  of 
about  340;  heat  27989  about  302;  heat  27993  about  293;  carbon  rail 
"A"  about  248,  and  carbon  rail  "B"  about  269. 

The  vanadium  steel  rails,  although  lower  in  carbon,  have 
greater  hardness;  and  hence  can  confidently  be  expected  to  give 
correspondingly  increased  resistance  to  wear  in  the  track. 


HARDNESS  TESTS 


VANADIUM  RAILS 

CARBON  RAILS 

Serial 
No. 

Rail 
26813-A 

Rail 
26813-B 

Rail 

27989-A 

Rail 
27993-A 

Rail 
A 

Rail 
B 

1 

302 

340 

286 

286 

241 

269 

2 

340 

340 

302 

286 

235 

269 

3 

340 

340 

302 

286 

248 

262 

4 

340 

340 

293 

286 

241 

269 

5 

311 

340 

286 

286 

228 

255 

6 

340 

340 

302 

293 

248 

269 

7 

340 

340 

307 

302 

255 

269 

8 

340 

340 

307 

302 

241 

269 

9 

340 

340 

307 

302 

241 

262 

10 

340 

340 

302 

293 

241 

269 

11 

340 

340 

302 

293 

241 

269 

12 

340 

340 

307 

302 

262 

269 

13 

364 

340 

311 

302 

255 

293 

14 

340 

340 

307 

302 

255 

269 

15 

340 

340 

307 

269 

217 

269 

16 

387 

340 

302 

293 

241 

302 

17 

387 

340 

293 

293 

248 

302 

18 

364 

340 

302 

286 

248 

302 

19 

364 

340 

302 

293 

248 

302 

20 

364 

332 

293 

293 

248 

302 

21 

364 

332 

293 

302 

248 

302 

22 

340 

332 

311 

311 

269 

269 

23 

340 

340 

311 

311 

269 

269 

24 

340 

340 

302 

307 

269 

286 

25 

340 

332 

311 

286 

255 

269 

26 

340 

340 

311 

293 

255 

269 

27 

321 

340 

311 

302 

262 

269 

28 

321 

332 

302 

311 

269 

269 

29 

321 

332 

311 

311 

255 

269 

30 

340 

332 

311 

307 

248 

269 

31 

340 

332 

302 

307 

241 

269 

32 

340 

332 

311 

302 

228 

269 

33 

332 

340 

311 

302 

241 

269 

34 

332 

340 

307 

302 

269 

269 

35 

332 

340 

293 

302 

255 

269 

21 


VANADIUM      RAILS 


WEAR  TESTS 

This  test  is  made  by  rotating  a  piece  1  in.  long  by  1  in.  diameter 
between  three  manganese  steel  rollers  of  3  in.  diameter.  The  two 
bottom  rollers  are  driven  by  gears  with  a  different  number  of  teeth; 
which  gives  the  rollers  different  speeds  and  causes  the  test  piece  to 
slip  as  well  as  rotate,  imitating  the  action  of  a  car  wheel  on  the  rail. 
The  tests  were  all  taken  from  the  head  as  shown  in  the  illustration. 

A  direct  load  of  110  Ibs.  is  applied  to  the  test 
piece  by  loading  the  top  roller.  In  previous 
tests,  a  load  of  220  Ibs.  was  used.  Owing 
to  the  great  tendency  of  soft  rails  like  carbon 
rail  "A"  to  flow  and  form  a  fin  or  bead  which 
gave  trouble,  the  weight  was  reduced  to  110 
Ibs.  It  was  found  that  the  abrasion  of  the 
test  piece  was  better  with  this  weight  than 
with  the  heavier  load.  The  test  pieces  were 
weighed  before  and  after  test.  The  loss  in 
weight  in  millegrams  was  divided  by  the 
original  weight  of  the  test  piece;  in  order  to 
Location  of  Wear  Tests  obtain  comparative  figures  and  allow  for 
variations  in  weight  of  test  pieces.  The  tests  which  follow  were  all 
run  50,000  revolutions: 


Heat 

Rail 

Milligrams  Loss 
Divided  by 
Weight  of  Test 

Relative 
Wear 

26813 
26813 
27989 
27993 
Carbon 
Carbon 

A-Crop 
B-Crop 
A-Crop 
A-Crop 
A 
B 

16.3 
13.1 

12.8 
12.2 
28.8 
21.1 

54 
45 
44 

42 
100 
73 

The  relative  wear  of  the  vanadium  steel  rails  is  practically  one- 
half  that  of  the  carbon  rails. 


CHEMICAL  ANALYSES  OF  RAIL  SECTIONS 
FREEDOM  FROM   SEGREGATION 

Chemical  analyses  were  made  of  rails  from  each  of  the  vanadium 
heats;  to  determine  whether  there  was  any  tendency  to  segregation, 
and  how  the  vanadium  steel  compared  in  this  respect  with  the  carbon 
steel.  For  this  purpose,  drillings  were  taken  from  two  locations  in  the 
head  of  the  rail.  One  sample  was  taken  from  the  top  corner  of  the 


VANADIUM      RAILS 


head,  corresponding  to  the  outer  portion  of  the  ingot;  and  the  other 
sample  was  taken  from  the  junction  of  the  head  with  the  web,  corre- 
sponding to  the  axial  center  of  the  ingot  where  any  segregation  present 
would  be  most  certain  to  be  found. 

There  is  no  segregation  in  the  case  of  the  vanadium  steel  rails, 
the  results  all  being  within  the  limit  of  analytical  error.  In  the  case 
of  the  vanadium  rails,  all  the  samples  were  taken  from  rail  crops. 


CHEMICAL  ANALYSES 


Heat 

No. 

Rail 

Location  of 
Sample 

Carbon 
Per  Cent. 

Manganese 
Per  Cent. 

Phosphorus 
Per  Cent. 

Sulphur 
Per  Cent. 

Vanadium 
Per  Cent. 

268  13 

A 

Corner  of  Head 
Top  of  Web 

.55 
.56 

1.49 
.52 

.015 
.015 

.023 
.022 

.147 
.148 

26813 

B 

Corner  of  Head 
Top  of  Web 

.54 

.57 

.46 
.49 

.016 
.017 

.022 
.021 

.144 
.147 

27989 

A 

Corner  of  Head 
Top  of  Web 

.52 
.52 

.11 
.11 

.013 
.013 

.022 
.024 

.150 
.150 

27993 

A 

Corner  of  Head 
Top  of  Web 

.56 
.57 

.73 
.74 

.019 
.019 

.023 
.024 

.158 
.159 

Carbon 

A 

Corner  of  Head 
Top  of  Web 

.72 
.79 

.67 

.68 

.035 
.047 

.028 
.038 

Carbon 

B 

Corner  of  Head 
Top  of  Web 

.74 
.81 

.68 
.69 

.011 

.012 

.035 
.041 

HOMOGENEITY  AND  DENSITY  (ETCHED  SECTIONS) 

Sections  from  the  rails  tested  were  polished  and  etched  in 
boiling  dilute  sulphuric  acid  and  photographed. 

The  time  required  for  etching  the  vanadium  steel  rail  sections 
was  several  times  longer  than  for  the  carbon  rails.  The  average 
time  required  was  about  30  minutes,  as  against  5  minutes  for  the 
"A"  carbon  steel  rail  and  about  15  minutes  for  the  "B"  carbon  steel 
rail.  The  difference  in  length  of  time  of  etching  is  also  a  very  good 
indication  of  the  comparative  resistance  to  wear. 


CONCLUSIONS 

From  the  results  of  the  tests  made  on  these  three  heats,  the 
American  Vanadium  Company  recommend  for  vanadium  steel  rails 
the  chemical  specification  given  on  the  following  page. 

23 


VANADIUM      RAILS 


This  specification  will  give  rails  with  30%  to  50%  higher  elastic 
limit,  or  useful  strength,  combined  with  greater  toughness  and  hard- 
ness than  simple  carbon  steel  rails  with  .62%  to  .75%  carbon  content. 
The  vanadium  steel  rails  will  show  even  greater  superiority  in 
comparison  with  lower  carbon  steel  rails  of  .45%  to  .60%  carbon. 

Carbon 45  to     .  60% 

Manganese 1 . 00  to  1 . 25% 

Silicon over  .  10% 

Phosphorus not  over  .  05% 

Sulphur not  over  .  05% 

Vanadium 4  Ibs.  added  per  gross  ton 

The  relatively  low  percentage  of  carbon  recommended,  together 
with  the  great  freedom  from  segregation  of  vanadium  steel,  should 
result  in  the  practical  elimination  of  the  danger  of  failure  from 
internal  fissures,  silvery  oval  spots. 


24 


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